Electrical connecter



" v c. G. JANsKY ELECTRICAL CONNECTER Sept. 18, 1928.

Filed 001;. 18, 1926 3 n Ue n 'For C aries 6i Ja 12E HJM wg] @n J m @LME Patented Sept, 1928.

UNITED lSTATES A Last-ssc PATENT oFFlcE.

cnnnnns e. JANsxY, or BERWYN, ILLINOIS.

nLEcrRIcAL CONNECTER.

Application tiled October 1.8, 1926. ySerial No.` 142,171.

. vision of novelyelectrical connecting means view of Figure 2, ishowing the. complete` terminal plug.

rpost.

enclosed in an insulating casing, and adequately insulated for handling while in use.

Another object of my invention is the pro'- vision of a novel'methodlof making or constructing electrical connecters of the class described.

Other objects and advantages of my invention will appear more Afully from the following description, taken in connection with the accompanying` drawings, in which similar characters of reference indicate similar parts throughout 'the several views. In the drawings accompanying this description:

Figure 1 isa view in perspective of' a modern 'B battery equipped with a connecter according to my. invention.

Figure 2 is an enlarged cross sectional view ofthe insulating frame and screw of my 'connecter I Figure 8 is an enlarged cross sectional view taken 'on a plane at right angles to the assembly of my connecter v, with a battery Figure 4 is an elevational view showing the molding core in position to form the Referring to` Figure 1, 10 indicates the modern B battery having the usual container 11, closed lby -an insulating cap 12, having a l,plurality 4of projecting terminal posts 13 and 14: for connection to the external circuit. The numeral 15 indicates my connecter inl its entirety, as shown in Figure 1,'consisting of an insulating body 16, which may be shaped by'cutting tools to the conforma'- tion shown in Figure 2, but which I prefer to 'construct by moulding the same of in-4 sulation such as bakelite, or other insulation having similar properties.

The insulating body 16 is providedwith a transverse opening 17, which may extend from one side into the said insulating body, if desired, but preferably extends through the same. The-insulating body 16 is also provided witha threaded bore 18, extending'A from one end transversely to the bore 17 connecting therewith, and preferably extending past the same to form a threaded pocket 19 on the opposite side of the borev 17. rIhe bore 18 is provided with a threaded insulating screw 20, which may also be made by the` use of cutting tools, ,but I`prefer to construct the lsame by moulding the insu- -lating screw 20 of balkelite, or insulation having similar properties, with'\the screw I thread moulded therein.

Extending from the bottom of the pocket 19 is a smaller bore 21, adapted to receive l an electrical conductor, and in the case of uninsulated wire, the bore 21 may be ex-v tended from the pocket -19 to the exterior of the insulatingA body 16. I prefer,'how ever, to use insulated wire with my` connecter, and for this reason the exterior end of the bore21 is enlarged 'as at 22, orl provided with a"counterbore 22. In the construction of connecters of small size I contemplate moulding the insulating body 16 `in finished conformation, with the exception of the small bore 21, which may be made 'by a single operation of drilling after moulding, but in the provision of connecters of larger size I contemplate moulding the insulating body 16 incomplete and linished form.

The insulating screw 20 which is moulded of insulation, as previously described, is

provided with a head 23, having a knurledl periphery 24 to permit manual grip in screwa ing the screw 20 to clamping position. The

exterior. surface 25 of the' head 23 may be also provided with indicia such as symbols `or plus and minus, which may likewise. be

moulded thereinland the depressions filled with a paint or other coating of ay color opposite to that of theinsulating body 16 and the head 23.

In furtherconstructin my. connecter, I insert the stripped end o an insulated wire 26 in the bore 21 with (the insulation 27 fitting into and filling the'fcounterbore 22. The stripped end of the wire 26 should preferably be of a length extendin from a bore 21, when in assembled' relation, into the threaded pocket 19. Although any type of wire may be used with my connecter, such as single strand wire, insulated or uninsulated, or stranded wire, insulated or uninsulated, braidedor twisted, I prefer to use l vinsulated stranded wire, and within the of the wire 26, intimately soldering the fused tions ,of the plug 31 extending from they threaded pocket 19 I splay or spread `out the strands ofthe wire 26 as at 27, in order to provide a better bond and contact, as will be further described.

I next fill the threaded pocket 19 by fusing lead or some'other non-corroding metal into the pocket, permitting the same to run into the pocket 19 about .the splayed end 27 metal with the end of the wire 26, 'and filling and overliowin the pocket'19, covering vthe adjacent side o the cross bore 17.

The use of a non-corroding metal forv the plug 31 of my connecter, aswell as any nsulating casing or clamping support of noncorroding material,l is a very important feature of my invention as with the connecters of the prior art the sulphuric acid and fumes therefrom quickly corrode 'the connecters at the point of contact and other points, increasing the contact resistance `and rendering disconnection ditlicult. However, my insulating casing may also be used with plugs of other metals to make conneeters which areinsulated in a manner not accom-v plished by`any of the devices of the prior art.

The cross bore 17 may then have its side 28, which is composed preferablyof lead' central portion and substantially straight` vsloping sides 20, in order to secure a maximum of contact with the majority of the conductors of various sizes, and a curved contact with terminals of the size 'adapted to t the curved portion 29. yThe rough poraperture 17 may then be trimmedloff flush with the external surface ofthe insulating.'

body like.

Another methodof forming the plug 31 which isthe referred -method, is as y. follows: `After tli casing has been constructed, asprevious'ly described, the screw 20 having been removed 16,/b'y filing, grinding, cutting, orv the 'I from the bore 18, amoulding core 33 of suitable material may be provided of such size and shape to ll that portion of the apere insulating non-corroding ture 17 adjacent the bore 18. 2 ',Ihe sha e of the core 33 should be such that it wi l .fill the aperture 17 and form the exposed sur-L face 29 of the plug 31 to the conformation the moulding core is placed -in vertical position or at a slight tilt for a purpose to be further described, the casing 16 may be placed thereon with the moulding core inthe aperture 17l and filling the right hand part thereof. f

The apron 34 previously mentioned should then close the lower part of the remainder of the aperture 17, forming a cup open at.

the top vconsisting of the pocket 19 and part of the aperture 17 and the wire 26 with its y splayed end 27 having'been previously arranged in the casing, the lead or other noncorrodingmetal, may be oured in the said cup filling the same to previously described'. In order to cause the lead to run down into pocket 19 that end of the casing may be tilted downward if de.

A sired, or air'pressure may be applied to the upper surface of the lead in the cup to force the lead into place in the manner used for casting dental inlays, as far as applicable. The plug 31 may thus be moulded with a `minimum of machining, having a surface l29.0f any shape desired, the preferred form being described above. It should be noted that the moulding core 33 may be made tol form the surface 29 exactly' to fit any ter- 'minal plug but the moulding c ore 33 used need not Anecessarily vbe the same size as the terminal.

It will thus be observed that my connecter,v

besides being particularly adapted to provide a `maximum areal o orm the plug 31 lin-es of VVcontact vwith terminals of larger.

size or a single line of contact with'terminals of smaller size. Furthermore, the soft metal plug 31 is peculiarly adapted. to shape its own surface in a measure to ,thesurface gages.

fr ,In thevuse of 'my connecter, the external.

for'connecting a plurality of conductors to' gether by clamplngthe'm all within the aperture 17, thereby establishing connection be- 4of the contact terminal with which 'it en- I corroding y'metal plug 31.-' Howe-Ver, I desire it to be understood that my connecter may `also be usedwith 'orwithout the wire 26 tween the conductors' so clamped, and-1 also between the said `conductors and the conducting plug connecter of small size and convenient shape;

l The screw head 23 should be of substantialv I also desire itto beunderstood that my connecter may be used without the clamping screw '20 4by using an aperture: 17 adapted to fit closely upon the tapering terminal post so that the terminal post 14 would be in effect, wedged into the aperture 17 with the post 14 in contact with the plug 31. The external shape `of the insulating ybody 16 may be of any desired conformation adapted tofhave sufiicient strength to support the parts previously. described, but I prefer to make the insulating body 16 yof substantially cylindrical shape, klwhich 4may be tapered to a smaller size about the wire 26, and the insulation 32, thereby providing a size vin order to permit a firm manual grip.

I further desire it to be understood. that the metal plug 31 may also be constructed of a shaped metal piece which is previously secured'to the end of the insulated wireI 27,

and which may be constructed by moulding struction set forth, 4but desire to avail myself lows:

, thereinto,

more, mA connecter is fully and adequately insulate and may be grasped by thejhands while in use without danger of` shock or.

'shortcircuit It will also be observed lthat I have provided a novel method consisting of a series of steps for the making of such a connecter.

While I havesliown and described a specific embodiment of my invention, it will be understood that many modifications thereof may be made without departingI from the spirit of the invention, and I do not desire to be limited to the precise details of conof all changes within the scope of the appended claims.' l i .Having thus described my'invention, what I claim as new and desire to secure by LettersPatent of the United States is as fol- 1. In anelectrical connecter, anon-corroding body portion,I having anVopen'ing y a 'threaded bore communicating therewith and providing a pocket b elow said opening, and a smaller bore leading from` said pocket out of said body.l anv electrical conductor extending'irom` said smaller bore l into said pocket, and a'non-corroding screw for-'clamping other conductors in contact wlth said first named conductor.

2. In an electrical connecter, a moulded insulating body portion having a recess therein and a threaded bore communicating with said recess and low said recess, a soit metallic plug fused into said pocket, filling the same and providing a wall for said recess, and a moulded insulating screw .for clamping conductors in contact with said plug. Y i 3. In an electrical connecter, a moulded insulating body havin a recess therein, a

roviding'a pocket bepocket in theone sidel t ereof, a smaller bore extending fromsaid pocket and a counterbore from said smaller bore to 'the exterior of said body, an insulated conductorl having its insulation within said counterbore, a

stripped end of said conductor in said smaller bore, a splayed end of said conductor in said pocket, and a fuse'd metallic plug connected with saidfend and filling said pocket.

4.,. In an electrical connecter, a moulded insulating body having a recess therein, a 'l threaded bore communicating with said recess and forming a pocket on the oppositev side thereof, a smaller bore extending from.

vsaid pocket 4and a counterbore'from said smaller bore to the exterior of said body,-

an insulated conductor-having its insulation within said counte'rbore, a-stripped end of said conductor in said smaller bore, a splayed end ofy said conductor in said pocket, a fused metallic plug connected with said end and filling said pocket, and an insulating screw for clamping conductors within saidv recess against said plug.

member with a recess therein vand an intersecting threaded bore having a pocket below said recess, filling the said pocket by fusing metal therein to form a vwall for said' recess,

. j v10u 5. The method-of making a connecter- Vcomprising, moulding an vinsulating frame and moulding a threaded screw to fit said threaded bore.

6. The method of making a connecter comprising, moulding an insulating frame member having a recess thereln andan aperture therethrough transverseto sald recess,

'a threaded'bore and y pocket below said recess, and a smaller bore,

pocket, fusing metal aboutl said conductor to fill said pocket and form a wall forsaid re'cess-and shaping said wall to conform to the shapeof a terminal member.

7; The method of constructing a connecter and intersecting said opening, and a smaller bore continuing said first-,bore through said frame, introducing'.` a stranded wire into said threaded" bore through said smaller bore, splaying `said. stranded wire in said threaded bore, and fusing metal about said introducing' an electrical conductor through said'smaller bore into said `communicating therewith and consisting of comprising, moulding an insulating :frame member having van openingextending .therethrough, a threaded bore `extending past wire to fill said bore and form a Wall for said opening. Y f

8. The method of constructing a connecter comprising, moulding any insulating Eframe member' having an opening extending therethrough, a threaded bore extending `past and intersecting said opening, and a smaller bore continuing said first bore through said frame, introducing a stranded Wire into said threaded'bore through said smaller `bore.

splaying said stranded Wire in said threaded bore, and fusing metal about said Wire, filling said bore up to and into saidv opening, and shapinflr said metal when hard to conform tothe'- shape of a terminal conductor.

9. The' method ofconstructing a connecter comprising, 'moulding an insulating frame member having an opening extending therethrough, a threaded bore extending past and intersecting `said opening, and a smaller bore continuing said first bore through said frame', introducing a stranded Wire into said threaded bore through said smaller bore, splaying said stranded Wire in said threaded bore, and fusing metal about said A wire, filling said bore up to and into said opening, shaping said metal When hardtoconform to the shape of a terminal connecter, and moulding aninsulating screwi to fit said threaded bore.

10. The method of constructing avconnecter comprising, moulding an insulating a counterbore extending from said smaller' bore through said frame, introducing the stripped end Iof' an insulated stranded wire 4into said smaller bore, the insulation being received `in said counterbore, splaying sai stranded Wire in said threaded bore and fusing metal about said Wire to fill said threaded bore toform a Wall for Isaid opening;

11. comprising, moulding an' lnsulatlng frame member with a recess therein and an inter-v4 secting threaded borehaving a pocket below. said recess, filling the said pocket byv fusingd non-corroding meta-1 therein to form a Wall .for said recess, and mouldinga threaded screw to iit said threaded bore.

In witness whereof, I hereunto subscribemy name this 14th day of Cctober, 1926,..

The method of making a connecter- CHARLES G. JANsxY; 

